Foundry binder comprising one or more cycloalkanes as a solvent

Abstract

A foundry binder comprising (a) a polyol component selected from the group consisting of phenolic resins, polyether polyols, polyester polyols, aminopolyols, and mixtures thereof, and (b) a polyisocyanate component, wherein component (a) and/or (b) further comprise, as a solvent, one or more cycloalkanes.

1 . A foundry binder comprising:
 (a) a polyol component selected from the group consisting of phenolic resins, polyether polyols, polyester polyols, amine polyols, and mixtures thereof,   (b) a polyisocyanate component; and   wherein component (a) and/or component (b) further comprise, as a solvent, one or more cycloalkanes selected from the group consisting of unsubstituted cycloalkanes, substituted cycloalkanes, and mixtures thereof.   
     
     
         2 . The foundry binder of  claim 1  wherein the polyol component comprises a phenolic resole resin. 
     
     
         3 . The foundry binder of  claim 2  wherein the number of carbon atoms in the cycloalkane is from 5 to 24. 
     
     
         4 . The foundry binder of  claim 3  wherein the number of rings in the cycloalkane is from 1 to 4. 
     
     
         5 . The foundry binder of  claim 3  wherein the number of carbon atoms in the rings of the cycloalkanes is from 4 to 10. 
     
     
         6 . The foundry binder of  claim 5  wherein one or more of the cycloalkanes has 2 rings. 
     
     
         7 . The foundry binder of  claim 2  wherein the cycloalkane is selected from the group consisting of cylcohexane, trimethyl cyclohexane, decahydronaphthalene, tetrahydronaphthalene, and mixtures thereof. 
     
     
         8 . The foundry binder of  claim 2  wherein the cycloalkane comprises decahydronaphthalene. 
     
     
         9 . The foundry binder of  claim 1 ,  2 ,  3 ,  4 ,  5 ,  6 ,  7 , or  8  wherein component (a) and/or component (b) further comprise one or more solvents selected from the group consisting of aromatic hydrocarbon solvents, ester solvents, fatty acid ester solvents, and mixtures thereof. 
     
     
         10 . The foundry binder of  claim 9  wherein the amount of cycloalkane in the binder system is from 5 to 40 parts by weight based upon 100 parts by weight of the binder. 
     
     
         11 . The foundry binder of  claim 10  wherein the amount of aromatic hydrocarbon solvents is less than 10 parts by weight based upon 100 parts by weight of the binder. 
     
     
         12 . The foundry binder of  claim 11  wherein the binder does not contain aromatic hydrocarbon solvents. 
     
     
         13 . A foundry mix comprising a major amount of a refractory and a minor amount of the foundry binder of  claim 9 . 
     
     
         14 . The foundry mix of  claim 13  which further comprises a liquid tertiary amine curing catalyst. 
     
     
         15 . A cold-box process for preparing a foundry shape comprising:
 (a) introducing a major amount of the composition of  claim 9  into a pattern to form a shape;   (b) contacting the shape with the vapor of a tertiary amine curing catalyst;   (c) allowing the shape to cure; and   (d) removing the shape from the pattern.   
     
     
         16 . A process for casting a metal part comprising:
 (a) inserting a foundry shape prepared in accordance with  claim 15  into a casting assembly having one or more molds and/or cores;   (b) pouring metal, while in the liquid state, into said casting assembly;   (c) allowing said metal to cool and solidify; and   (d) then separating the cast metal part from said casting assembly.   
     
     
         17 . A metal casting made by the process of  claim 16 . 
     
     
         18 . A no-bake process for preparing a foundry shape comprising:
 (a) introducing a major amount of the composition of  claim 14  into a pattern to form a shape;   (b) allowing the shape to cure; and   (c) removing the shape from the pattern.   
     
     
         19 . A process for casting a metal part comprising:
 (a) inserting a foundry shape prepared in accordance with  claim 18  into a casting assembly having one or more molds and/or cores;   (b) pouring metal, while in the liquid state, into said casting assembly;   (c) allowing said metal to cool and solidify; and   (d) then separating the cast metal part from said casting assembly.   
     
     
         20 . A metal casting made by the process of  claim 19 . 
     
     
         21 . A heat cured process for preparing a foundry shape comprising:
 (a) introducing a major amount of foundry mix comprising a (i) refractory, (ii) a novolak resin and (iii) a polyisocyanate into a heated pattern to form a foundry shape,
 wherein component (ii) and/or component (iii) further comprise, as a solvent, one or more cycloalkanes selected from the group consisting of unsubstituted cycloalkanes, substituted cycloalkanes, and mixtures thereof; 
   (b) allowing the foundry shape to cure; and   (c) removing the foundry shape from the pattern when it is handleable.